Today, packaging is no longer just about protecting a product. Increasingly, it serves as a carrier of emotion, a brand differentiator, and an element of user experience. This was the approach taken by the owner of a major glass packaging company, who came to us with a bold idea — integrating LED lighting directly into the surface of a glass bottle.

From the very beginning, we knew this would not be a standard project. The goal was not to create a visually striking “demo” prototype, but a solution that could be realistically implemented in large-scale production — without traditional PCBs, additional housings, or aesthetic compromises. From a technological standpoint, this meant one thing: the entire electronics system had to “disappear” into the form while functioning as reliably as conventional circuit-mounted solutions.

A project requiring more than just technology

Although the client was a leader in their industry, printed electronics was entirely new to them. This meant our role went beyond delivering a technology — we had to guide the entire process, from concept and material selection to preparing a solution ready for automated production.

The biggest challenge was bridging two worlds: delicate, smooth glass and precise electronics. Glass does not forgive mistakes — a minor variation in the process could result in print delamination, unstable contact, or visual defects. Meanwhile, the electronics required repeatability and a “clean” connection: SMD LEDs had to be mounted directly on the bottle, and printed traces had to be durable, electrically stable, and visually appealing.

A prototype that set the direction

We began with rapid prototyping, creating a physical model of the illuminated bottle. This allowed both us and the client to verify the project assumptions at full scale. This stage was crucial, as it revealed the complete context: how light interacts with the glass, how component integration looks, and what truly creates an impression versus what only looks attractive in theory.

It was a breakthrough moment — the vision became tangible, and the prototype clearly indicated that SMD LEDs should be mounted directly on the glass, without intermediate layers. For product marketing, this was excellent news, preserving the purity of the form. For technology, it highlighted the key task: optimizing materials and processes to ensure durable, repeatable glass mounting.

Materials engineering instead of off-the-shelf solutions

It quickly became clear that commercial silver pastes did not meet our requirements. Adhesion issues and print durability risks could lead to unstable electrical connections — unacceptable in mass production.

We therefore developed a dedicated, chemically-curable conductive silver, specifically designed for this project. Our proprietary formulation enabled us to:

• achieve stable adhesion to glass surfaces,
• ensure reliable electrical contact with SMD LEDs,
• utilize the client’s existing high-temperature ovens for curing.

This was also a business-critical element. Implementing the technology did not require a complete infrastructure overhaul — we could rely on what the client already had rather than starting from scratch. This made the solution both technically effective and feasible for industrial deployment.

Scaling the project and automating the process

Once the technology was perfected at the lab level, the most challenging stage followed: preparing it for large-scale production. Manual component placement did not provide the required repeatability or throughput.

We organized a Pick & Place technology demonstration and then collaborated with an external company specializing in industrial machinery. Together, we designed a dedicated Pick & Place machine tailored to the specifics of glass bottles and printed electronics.

The result was a device capable of precise, repeatable placement of LEDs on every bottle, eliminating the risk of human error at this critical stage.

Implementation and technology mentorship

The final phase — launching the technology on the production line — verified all previous assumptions. The client’s lack of experience with printed electronics led to questions, adjustments, and unexpected operational challenges.

At this stage, we acted as technology mentors, providing on-the-spot support, troubleshooting, and knowledge transfer to enable independent work with the technology. Through this collaboration, the client not only launched production but also gained full autonomy for future operations.

A moment of truth for the technology — and for Qwerty

This project confirmed what we have observed for some time: printed electronics on glass is no longer just an experiment or a laboratory concept. With the right approach, it can become a stable, repeatable element of industrial production.

For us, it was a project where we combined technological expertise, materials engineering, and practical understanding of production processes. From the first prototype to automation — every stage mattered.

If you are considering printed electronics in your product, start with a simple question: do you want a striking prototype, or a solution ready for implementation? We help guide this journey in an organized way — from concept validation, through materials and processes, to automation and stable production.

If you’d like to discuss a similar project, reach out to Qwerty. We will quickly assess what is technologically feasible, identify risks, and plan a process that works not just “in theory,” but in real-world production.